Insulated wall module

ABSTRACT

The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site as technical design of the load bearing steel truss of the defined height, width and thickness, made of appropriate shaped steel elements, of appropriate dimensions, positioned appropriately to form the structure and fixed in compliance with all relevant requirements of the professional building practice and regulations. Steel elements are mostly C elements, horizontal ( 1.1 ) and vertical ( 1.2 ) C elements with fastening mechanisms fastened on the outside horizontally ( 2.1 ) and vertically ( 2.2 ) with internal ( 1.3 ) and external ( 1.4 ) spacers positioned on their sides of low thermal conductivity, on which internal ( 6.2 ) and external ( 6.3 ) lining panels are placed of the appropriate thickness defining in such manner the total thickness of the wall. The complete wall is factory-built so that the developed steel structure with all needed installation channels built in and with placed lining panels is placed in the appropriate press to inject expanded polyurethane in the space between the lining and the outside line of the steel structure that forms the wall, at approximately 3-bar pressure, which then expands and squeezes out the air from within the structure thereby creating a compact fill mass eliminating any risk of damp and condensation in the wall, at the same time improving for at least 30% the statics of the steel structure. In this way a full compact wall of precise dimensions is built in a factory to the full completion with all ceramic tiles and parquet flooring, with all needed installation channels built in, with all openings including window and door openings of excellent insulation properties with the heat penetration coefficient U of approximately 0.14 W/(m2K°) which is less than 0.15 W/(m2K°) as the limit value for the compliance with passive house characteristics. Walls produced in entirety or in segments according to the described invention are transported to the site and installed, all the walls or their segments are joined, with fastening mechanisms vertically and horizontally, to make complete building structures. Because this invention allows the precise building of walls, in entirety or in segments, their installation after the transport on site is easy, based on precisely defined figures and methods, with the minimum labor and in a short time period, with only a few tools and equipment needed for the job. If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility channels and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept with additionally reduced building costs.

1. TECHNICAL FIELD

This invention: a wall module of superior insulation properties for passive buildings, a technique of manufacture of a product provided with all needed installations, through application of the appropriate technological process, easy to install on a building site—encompasses the technological domains marked as E04B 2/58, E04C 1/00 and E04C 2/00 according to the International Patent Classification.

2. TECHNICAL PROBLEM

Professionals continuously endeavor to achieve as minimum as possible consumption of material and time and as low as possible building costs per surface area unit of structures in combination with the optimum characteristics of structures and this has been a constant technical challenge in the technological field in question.

It is a well known fact that the price, quality and characteristics of a structure are mostly conditioned by the technical design of walls, therefore by their structure, therefore, methods have been developed to produce walls as finished structures, to the maximum possible extent and to find options for their as economical as possible installation at the building site. Naturally, the success of finding the above indicated technical solution is predominantly conditioned by the successful technical design of the wall and the manufacturing technique as well as installation methods used in the building construction operations.

The technical problem resolved in the subject invention consists of the definition of such wall structure and of the application of such materials and making and building techniques, to achieve excellent insulation properties of the wall needed for the construction of passive buildings with at the same time meeting all the requirements of the professional building practice and the regulations with respect to the strength and the statics of walls and of the entire building. It would be preferable here to make sure also that the appropriate technological process is used such that the finished wall can be made in factory complete with ceramic tiles and parquet flooring, with all needed installations, all openings including door and window openings. The simple and fast installation of a building on a building site with a low labor cost will reduce significantly building costs per surface area unit of the building.

In order to make sure that passive house standards are fulfilled, this has been confirmed with the “Blower-Door-Test”, all external elements of the building except glazed surfaces should have such thermal insulation for the heat penetration coefficient U not to exceed 0.15 W/(m²K), whereby the needed thermal energy does not exceed 15 kWh/m².

The prerequisite for the completion of a passive house is the technical design of the entire envelope of the building with thermal insulation of the appropriate quality, fully compact, i.e., almost hermetically closed building envelope. This means that edges, angles, joining points and openings must be designed in such manner that as consequence all thermal bridges are eliminated to prevent the loss of valuable heat through joints and various openings.

This means that high and demanding standards will be set for the technical design of walls as structure components that have a prevailing impact on the resulting excellent insulation properties of individual sections or the building in entirety, achieved thanks to the quality of used materials, which, accompanied by adequate performance, allow the achievement of characteristics specific to passive houses.

It is preferable for the building walls to be made as a light load bearing steel structure filled with light material of excellent insulation properties, polyurethane (PIR) a fire-retardant, and for the walls to be of the appropriate thickness and of appropriate rectangular dimensions (one-floor elevation): higher than 2 m and of the appropriate width.

3. STATE OF THE ART

Historically, people have continuously endeavored to achieve as low as possible consumption of materials and time in combination with as low as possible building cost per surface area unit of a structure, with the optimum characteristics of the structure, mostly with respect to insulation properties which guarantee the lowest possible consumption of heating sources per square meter of residential surface, which includes: solid materials, gas, heating oil or electricity.

A possible reduction of the building cost depends directly on the wall structure that requires the adequate consumption of materials, and it depends in particular on the extent to which the wall can be factory-built and on the extent of the remaining work that needs to be done at the building site.

Lately, the focus has been put on efforts to achieve such insulation properties of a building for the needed heating energy value not to exceed 15 kWh/m² per year, which is a vital feature of structures called passive houses. Studies and works have been done for over two decades now in the area of passive houses and it is clear that in order for the passive house to be completed some high and demanding standards need to be met in terms of the quality of components of the house. Therefore, all external elements of the house, except glazed surfaces, need to have such thermal insulation for the heat penetration coefficient U not to be higher than 0.15 W/(m2K).

The passive house is a result of a low-energy house development cycle (NEK). The passive house consumes up to 80% less energy compared to a low-energy house and up to 90% less energy compared to conventional building structures.

The uncontrolled exchange of the external and internal air must be prevented in passive houses, which can be achieved through excellent thermal insulation and a compact structure of individual components and of the entire structure.

This means that outside surfaces of a building must allow the full sealing of its insulation envelope for them to form jointly a sort of a wind-tight surface. In addition, joining points of all structural elements and utility channels must be made carefully to ensure the needed wind tight property is achieved. Edges, angles, joints and openings must be done properly to avoid thermal bridges.

Structures performed according to such quality standards not only prevent draught and the loss of energy, but the reduced penetration of damp into structures reduces substantially the risk of damage on the building's structural elements.

Therefore, the design and work on a passive house for builders is a much more complex task than the design and work on, in terms of dimensions and functions, an equivalent traditional building.

The thickness of the passive house insulation should be at least 55 to 60 cm in combination with the placement of triple glazed windows and doors of appropriate thermal insulation properties.

The “Blower-Door-Test” is used to check whether a structure meets the passive house building standards. All external elements of the building, except glazed surfaces need to have such thermal insulation for the heat penetration coefficient U not to exceed 0.15 W/(m2K).

The state of the art, in terms of achieving excellent insulation properties of buildings, has given some building techniques that use light wall elements.

Wall elements are mostly made of expanded polystyrene. Examples of these techniques and their resulting structures have been published in U.S. Pat. No. 5,353,562, U.S. Pat. No. 4,823,534 and U.S. Pat. No. 5,617,686.

EP 0 727 535 A1 is the partition wall building technique that involves the use of a large number of posts and steel elements, securing the position of main surface materials on both sides of the element with the noise insulating material and hard gypsum panels as reinforcement for the principal external surfaces, making a fireproof wall structure.

U.S. Pat. No. 5,765,333 describes the system of building using posts and panels that are joined such that the post is placed on the floor, a solid foam panel, consisting of one or several glued layers of solid foam shaped to fit the post placed next to the beam and joined with the beam and the floor, thereafter the following post is placed and joined with the same panel etc. Prefabricated strips may be placed on the surface of panels, to join gypsum panels on the inside of the wall structure, or as a fixing element on the outside.

There are several types of bearing wall structures mostly made at the passive house building site but the quality of the wall fill, from the technical and technological aspect, is lower.

There are also modules, US2010242394(A1) and WO2010111945 (A1), that are somewhat similar to the subject invention but different in terms of several essential properties.

4. ESSENCE OF THE INVENTION

The importance of the invention is in its technical design that resolves the indicated technical problem by defining the load-bearing steel structure of the wall with all the appertaining components and all needed installations and openings for a specific structure intended for a specific purpose, of specified dimensions and location, of the specific layout of premises, after the completion of appropriate calculations, according to well known methods, and in compliance with the principal requirements set by the building regulations, such as pressure strength, earthquake, wind resistance and fire safety properties, which in the end allows in terms of technology, the development of complete walls, factory made, simple installation of these walls on the building site with the characteristics and qualities in compliance with the criteria set to meet passive house standards.

Such a defined steel structure consist of elements of specified shapes and dimensions, in general of C elements, horizontal 1.1 and vertical 1.2, C elements made of steel metal sheathing of the appropriate thickness and appropriately joined, according to the established work method, with in the middle additional steel elements for reinforcement 8.1, as suitable, for additional strength, according to calculations, and in addition to horizontal 1.1 and vertical 1.2 C elements.

The suitable wall fasteners or their elements are fixed inside horizontal 1.1 and vertical 1.2 C elements, according to calculations done in compliance with all relevant building practice requirements and regulations, to fasten walls or their segments horizontally 2.1 and vertically 2.2 with fasteners.

Horizontal and vertical wall fasteners consist of a clamping screw, with a body 3.2 and a head 5.1, of a fastener cylinder 3.1 with a housing for the C element and a nut 3.3 with a housing for the C element.

The fastener cylinder 3.1 with a housing and a nut 3.3 with a housing are placed on the C element in a position, as allowed by the internal surface 4.1 at the bottom of the C element and two internal side surfaces 4.2 of the C element such that neither the fastener cylinder 3.1 nor the nut 3.2 ever protrude beyond the volume of the C element and so that they are always at a distance D from the edge 3.4 of the C element—fastening the wall either horizontally or vertically.

The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing, are placed on the C element, as described above, laid in the direction of the axis 4.3 of the C element, and as a rule placed in the corner to lean against and be fixed on the internal surface 4.1 at the bottom of the C element and on the appropriate internal side surface 4.2 of the C element, for better and more compact joining of elements.

Such a developed steel structure of a wall or of its segments is of a specific thickness 2.4, which in compliance with calculations is sufficient for any requirements set with respect to a specific building. The needed number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed on appropriate points of horizontal 1.1 and vertical 1.2 C elements.

The internal 1.3 and external 1.4 spacers are made of materials of adequate thermal insulation properties to eliminate thermal bridges between the outside and inside wall surface.

The internal 8.2 and external 8.3 lining is placed on the internal 1.3 and external 1.4 spacers, in which way a space is left between the internal 8.2 and external 8.3 lining to inject insulation fill 8.4 thereby obtaining the total thickness 2.5 of the wall or of its segments of such dimensions that depend on the intended use of the building premises and the set requirements, which may be approximately 200-400 mm, most frequently approximately 300 mm.

Holes are drilled on the internal 8.2 and external 8.3 lining at such position to match the internal 1.3 and external 1.4 spacers.

The wall or segment steel structure made in the above mentioned way, complete with spacers, fasteners and final lining, of the specified external volume, dimensions and the surface, for example of 36 m², is placed in the frame of the matching dimensions and the appropriate pressurized (for example 3 bar) injection press is used to inject the suitable insulation fill, most frequently expanding polyurethane, which expands spontaneously and squeezes the air out hermetically filling every inch of the space between two end panels and between boundary surfaces of the steel wall structure or of the wall segment, formed by appropriate elements, mostly horizontal 1.1 and vertical 1.2 C elements.

In this way the structure of the wall is completely compact ensuring excellent insulation properties with the heat penetration coefficient U not higher than 0.15 W/(m²K⁰).

A module is the usual word used for a wall structure made according to the above specified method by using a press, either for complete walls or their segments. Modules, in general, are of a rectangular shape usually of the total surface area of 36 m², 3×12 m in height and width, thereby meeting practically all the requirements encountered in practice.

If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility penetrations/channels and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept with additionally reduced building costs.

These wall modules, completely factory-made in the described manner, are then installed within the building construction process, on the building site such that they are joined horizontally and vertically with fasteners.

After the placement of the lower bearing module 10.1 of the wall on the foundations prepared in advance, the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.

5. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a Essential Steel Structures

-   -   Position 1.1: Horizontal C element;     -   Position 1.2: Vertical C element;     -   Position 1.3: Internal spacer;     -   Position 1.4: External spacer;

FIG. 1 b Examples of parts of the made steel structure segment

FIG. 2 a Steel structure with fasteners

-   -   Position 2.1: A part of the fastener for horizontal fastening of         walls or their segments;     -   Position 2.2: A part of the fastener for vertical fastening of         walls or their segments;     -   Position 2.3: Channels for the installation of pipes and         utilities;     -   Position 2.4: Thickness of the steel wall structure;     -   Position 2.5: Total thickness of the finished wall     -   Position 2.6: Channels for clamping screws;

FIG. 2 b Examples of developed steel structures with fasteners

FIG. 3. Wall or wall segment fastener assemblies

-   -   Position 3.1: The fastener cylinder with the housing to be fixed         to the C element;     -   Position 3.2: Clamping screw;     -   Position 3.3: The fastener's nut with the housing to be fixed to         the C element;     -   Position 3.4: The edge of the C element;     -   Position L: The total length of the C element;     -   Position D: The distance of the fastener, the cylinder or the         nut from the edge of the C element;     -   Position W: The distance between the axes of two C elements with         wall or wall segment fasteners;

FIG. 4. The position of wall fasteners fixed to the C element

-   -   Position 4.1: The internal surface of the bottom of the C         element;     -   Position 4.2: Internal side surfaces of C elements;     -   Position 4.3: The axis of the C element;

FIG. 5. The assembly of the clamping screw and the fastener cylinder with the housing to be fixed to be C element

-   -   Position 5.1: The head of the clamping screw;

FIG. 6. The assembly of the clamping screw and the fastener nut with the housing to be fixed to the C element

FIG. 7. Examples of installed fasteners for vertical and horizontal fastening of walls or their segments

FIG. 8. Essential wall components

-   -   Position 8.1: Steel structure elements, C elements and         reinforcements;     -   Position 8.2: Internal lining;     -   Position 8.3: External lining;     -   Position 8.4: Insulation fill;

FIG. 9. Cross section of the wall

-   -   Position 9.1: Internal support of the facade;     -   Position 9.2: External support of the facade;

FIG. 10. Examples of joined wall segments

-   -   Position 10.1: Lower load-bearing module of the wall;     -   Position 10.2: Upper load bearing module of the wall;     -   Position 10.3: Floor module of the wall;     -   Position 10.4: Upper partition wall;     -   Position 10.5: Lower partition wall;

6. DESCRIPTION OF ONE MODE FOR CARRYING OUT OF THE INVENTION

The subject invention has been developed such that the appropriate calculation has been done, according to the known and established method, in compliance with all the essential requirements defined in building regulations, such as pressure strength, resistance to earthquakes, wind and fire safety, relating to a specified structure intended for a specified purpose, with specified dimensions and the location, the layout of premises; a load bearing steel structure of the wall has been defined in such manner with all components and all channels and openings needed for installation of plumbing and other installation elements, allowing the application of the technology of completely factory-built walls, easy to install on the building site fulfilling all the criteria of passive house building standards.

Such a defined steel structure consists of elements of specified shapes and dimensions, mostly C elements, horizontal 1.1 and vertical 1.2 C elements made of steel sheathing of the appropriate thickness and joined appropriately according to the well-known method, with additional steel reinforcement elements 8.1. between them, as needed, for additional strength, according to calculations.

In accordance with calculations made in compliance with all relevant rules of the building practice requirements and regulations, suitable wall or wall segment fastening mechanisms are fixed inside horizontal 1.1 and vertical 1.2 C elements, for horizontal 2.1 and vertical 2.2 tightening and joining of walls or their segments.

The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element inside the space defined by the internal surface 4.1 of the bottom of the C element and two internal side surfaces 4.2 of the C element, such that neither the fastener cylinder 3.1 nor the fastener nut 3.2 ever protrude beyond the volume of the C element but they are at the distance D from the edge 3.4 of the C element whether used for vertical or horizontal tightening.

The fastener cylinder 3.1 with the housing and the fastener nut 3.3 with the housing are placed on the C element as indicated above, laid in the direction of the axis 4.3 of the C element, located in general in the corner and fixed appropriately to the internal surface 4.1 at the bottom of the C element and the respective internal side surface 4.2 of the C element, to give more strength to the joined segment.

Such a developed steel structure of the wall or of its segments is of the specified thickness 2.4, sufficient according to the calculation for a specific building. The appropriate number of suitably shaped internal 1.3 and external 1.4 spacers are placed and fixed at the specified points horizontally 1.1 and vertically 1.2 on the C elements.

Internal 1.3 and external 1.4 spacers are made of such materials that are of appropriate thermal insulation properties to eliminate thermal bridges between external and internal surfaces of walls.

The internal 8.2 and external 83 linings are placed and fixed onto the internal 1.3 and external 1.4 spacers, in which way the space is left between the internal 8.2 and external 8.3 lining in which the insulation fill is injected 8.4 to make up the total thickness 2.5 of the wall or its segments, whose dimensions depend on the intended use of the building and the corresponding requirements, which most frequently may be up to 300 mm.

Holes are bored on the internal 8.2 and external 8.3 lining to match the location of the internal 1.3 and external 1.4 spacers.

The steel structure of the wall or of its segment made as described above, complete with spacers, fastening mechanisms and final lining elements, of the specified outside volume and surfaces, for example of 36 m², is placed in the frame of the appropriate dimensions and the appropriate, for example, 3-bar, injection press technique is applied to inject insulation fill, most frequently expanded polyurethane, which expands spontaneously while the pressure squeezes out the air hermetically sealing the space between placed final panels and boundary surfaces of the steel structure of the wall or of its segments, consisting of elements, mostly, horizontal 1.1 and vertical 1.2 C elements. Because of such compact wall structure the statics of the steel structure is improved for at least 30%.

In such way a fully compact wall structure is achieved of excellent insulation properties such that the heat penetration coefficient U of the wall does not exceed 0.15 W/(m²K⁰).

The module is the usual name for the wall structure obtained after the application of the press technique in the above mentioned way, both on complete walls or their segments. Modules, in general are rectangular in shape, usually of the total surface area of 36 m², 3×12 m in length and width, meeting practically all requirements encountered in practice.

If all such modules, i.e., all wall elements are factory-made, with all windows, doors, utility channel and/or other additional elements installed in the production facility, one can make in advance the entire structure before it is brought to the building site, which results in a very flexible building concept and an additional reduction of building costs.

These wall modules, completely factory-made in the described manner, are then installed within the building construction process, on the building site such that they are joined horizontally 7.1 and vertically 7.2 with fasteners.

After the placement of the lower bearing module 10.1 of the wall on the foundations prepared in advance, the floor module 10.3 of the wall is placed and thereafter the upper bearing module 10.2 of the wall and partition walls, upper 10.4 and lower 10.5.

Internal facade supports are then fixed onto the steel structure, as necessary, followed by the installation of external facade supports (9.2) lying on the external lining (8.2).

7. INDUSTRIAL APPLICABILITY OF THE INVENTION

The subject invention can be applied in the construction industry and achieve the highest possible flexibility of building, beyond any comparison, with the radically reduced building costs and time schedules, which is a natural result of a process in which all modules, i.e., all wall elements are factory built with all windows, doors, installation channels and/or other additional equipment installed in the production facility, which means that the entire structure can be built in advance, before it is transported to the building site.

In addition, the subject invention allows the building of walls of excellent insulation properties of the heat penetration coefficient U not higher than 0.15 W/(m²K⁰), whereby the subject invention may be relevant in current construction achievements in the building of passive houses fulfilling the parameters and characteristics in compliance with the strictest standards. 

1. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site includes the technical design of the load bearing steel truss for a specific structure intended for a specific purpose, of specified dimensions, the location and the layout of premises, based on the appropriate calculations done according to the established method, in compliance with all essential requirements set in the building regulations, such as pressure strength, resistance to earthquake and wind, fire safety, defining the load bearing steel structure of the wall with all appertaining components and all needed door and window openings, but also with channels for all needed installations, for example electricity and telecommunications with installed plumbing and sewer installations, whereby such defined steel structure consists of elements of the determined shape and dimensions, mostly C elements, horizontal (1.1) and vertical (1.2) C elements, made of steel sheathing of the appropriate thickness and appropriately joined according to the established method, and between them, as necessary, to provide additional strength, according to calculations, additional steel reinforcement elements (8.1) are built, in addition to horizontal (1.1) and vertical (1.2) C elements, characterized in that suitable wall fasteners are fixed inside specified horizontal (1.1) and vertical (1.2) C elements of the steel structure, in accordance with calculations made according to all relevant requirements of the building profession and the regulations, in walls or their segments to fasten/tighten the walls horizontally (2.1) and vertically (2.2) with fasteners, whereby the fastener cylinder (3.1) with the housing and the fastener nut (3.3) with the housing are placed in the C element inside the space defined by the internal surface (4.1) at the bottom of the C element with two internal side surfaces (4.2) of the C element such that neither the fastener cylinder (3.1) nor the fastener nut (3.2) protrude in any way beyond the volume of the C element but they are at the distance (D) from the edge (3.4) of the C element, when fastened horizontally or vertically, and the fastener cylinder (3.1) with the housing and the fastener nut (3.3) with the housing, are laid in the direction of the axis (4.3) of the C element, placed, in general, in the corner to lean against and be fixed appropriately to the internal surface (4.1) at the bottom of the C element and the corresponding internal side surface (4.2) of the C element, in which way they are joined more firmly.
 2. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site according to patent claim 1, characterized in that at the specified points of horizontal (1.1) and vertical (1.2) C elements, the needed number of suitably shaped internal (1.3) and external (1.4) spacers are placed and fixed, which are of such design and material properties that may serve for good thermal insulation.
 3. The construction of a wall module of superior insulation properties required for passive buildings, the method of its industrial production for easy to install at erection site according to patent claims 1 and 2, characterized in that the internal (8.2) and external (8.3) lining placed on internal (1.3) and external (1.4) spacers, with suitable holes bored to match the location of internal (1.3) and external (1.4) spacers.
 4. The method of industrial production of wall modules of superior insulation properties for passive houses, of the specified outside volume and surface of the steel wall structure, of for example 36 m², made according to patent claims no. 1, 2 and 3, characterized in that the structure is placed in the frame of the matching dimensions, in the appropriate pressurized, for example 3-bar, injection press, with corresponding insulation fill, most frequently expanding polyurethane (PIR), which expands spontaneously and squeezes out the air under pressure, thereby sealing every inch of the space defined by final panels and boundary surfaces of a steel wall structure or its segment, consisting of the corresponding elements, mostly horizontal (1.1) and vertical (1.2) C elements.
 5. The procedure of installation of wall modules of superior insulation properties, factory built according to patent claims 1, 2, 3 and 4, for building development on site on the foundation prepared in advance characterized in that installation done with modules joined with horizontal and vertical fastening mechanisms such that the lower bearing module (10.1) of the wall is placed on the foundations prepared in advance, followed by the floor module (10.3) of the wall and the upper bearing module (10.2) of the wall with partition walls, upper (10.4) and lower (10.5). 